Molded pulp carton



April 4, 1961 2,978,162

H. E. LAMBERT MOLDED PULP CARTON Filed Feb. 9, 1959 2 Sheets-Sheet 1@mwmm 2mm: 7

April 4, 1961 H. E. LAMBERT MOLDED PULP CARTON Filed Feb. 9, 1959 UnitedStates Patent j:

MOLDED PULP CARTON Harry E. Lambert, Gary, Ind., assignor to PackagingCorporation of America, a corporation of Delaware FiletlFeb. 9, 1959,Ser. No. 792,017 13 Claims. (Cl. 229-25) The present invention relatesto an improved type of molded pulp carton and has especial reference tomolded pulp egg cartons of the elongated type used in the packaging ofeggs, of which the two-by-six car-ton is one ex- 'ample.

Egg cartons of the type mentioned are extensively used in the packagingof eggs. Frequently the filled cartons are stacked one on top of theother, either .during the shipment thereof in the so-called standard eggcases, for display and storage purposes in stores, and for otherpurposes. One form of such carton comprises two sections, bottom andtop, hinged along one margin. It is preferable that only the bottomsection be provided with cells to receive the eggs and that the upperwall of the top section be formed primarily of a fiat panel or panels.Such construction facilitates the stacking of the cartons and alsoprovides broad surfaces on which advertising indicia can conveniently beimpressed.

Customers at times desire but one-half the number of eggs which theentire carton contains, and in certain prior cartons the construction issuch that the carton can be divided transversely into two sections.

In prior constructions the cartons of this type, when comprised of buttwo sections, have been relatively weak, particularly in the coversection, and this has resulted in the breaking of eggs at times.

in some prior constructions more than two sections have been provided inan attempt to provide a more rigid construction. However, suchconstructions increase the cost, increase the size so that it is notpossible to pack the required number in a standard egg case, and areother objectionable.

'One of the objects of the present invention is to provide an egg cartonconstruction which can be produced at reasonable cost and which willrigidity the carton,

particularly the cover section, in such manner as to prevent thebreakage of eggs when the filled cartons are stacked as in shipping orstorage and handled in the channels of trade.

Another object of the invention is to provide an egg carton of this typewherein the structure is such that it is feasible to mold the same fromthe usual pulp stock, all portions being so disposed as to provide therequisite draft angles.

Still another object of the invention is to provide an egg cartonconstruction which, while provided with a transverse depression at themiddle, which will facilitate dividing the elongated carton into twosections each containing one-half the total number of eggs, when dividedwill assure a considerable portion at each end of each divided sectionas a wrap-around sufficient fully to protect the eggs at each end ofeach section from the likelihood of inadvertently being displaced fromthe carton.

Again it is an object of the invention to provide an elongated-type eggcarton adapted to be divided transversely to form two or more cartons,each with a fractional part of the total number of eggs and which shallPatented Apr. 4, 1951 be so constructed that even though the filledcarton be lifted by gripping entirely at one end, the longitudinalrigidity will be such as to prevent collapse of the carton with theconsequent danger of egg loss. or damage.

Other objects of the invention will be clear from. the followingspecification and by reference to the accompanying drawings illustratinga preferred embodiment and inwhich:

Fig. 1 is a front elevational view of a carton embodying the invention;

Fig. 2 is a top plan view;

Fig. 3 is a view in end elevation;

Fig. 4 is a plan view depicting the carton of Fig. 1 in open position,being the form in which it leaves the molding machine;

Fig. 5 is a transverse vertical sectional view on the line 55 of Fig. 4viewed in the direction of the arrows;

Fig. 6 is a view of the carton as divided along the line 66 of Fig. 1;and

Fig. 7 is a longitudinal sectional view of the cover section along theline 77 of Fig. 4.

As shown, the carton is designed to hold one dozen eggs in the form oftwo rows of six eggs each. Hence, the carton is of elongated shape. Thecarton which is formed of molded pulp stock comprises a body having alower section or bottom 10 and an upper section or top 11, the sectionsbeing united along one margin by an integral hinge 12 which permits thetop to be folded over the bottom.

The bottom section 10 is provided with a flap 13 along its front margin,which is hinged at 14 to the bottom and is thereby adapted to be foldedfrom the plane shown in Fig. 5 to the locking position inside the frontwall of the top section 11, when the carton is in closed position.

The front wall 15 of the top section is provided With a plurality ofopenings 16 adapted to receive projections 17 on the flap 13, when thecarton is in closed position, then serving to hold the top and bottomsections against accidental separation.

By reference to Figs. 1 and 6, particularly, it will be observed thatthe upper marginal portion 18 of the locking flap 13 terminates wellbelow the underside of the panels 2fl-20 of the top or cover 11 and alsobelow the transverse cross wall portion 21 at the center of the cartonwhere the carton is adapted to be divided. As will be explained later bythis construction, there is no likelihood of the upper marginal portionof the locking flap preventing the full engagement of the marginalperipheral portions of cover and bottom sections, as well as other partsof cover and bottom sections which are designed for supportingengagement one with the other. The bottom section It) is provided with aplurality of egg cells formed by a central row of hollow upstandingposts 25. These posts may vary in construction, those shown being by wayof illustration and not by way of specific limitation. However, thearangement is such that there is one post 25C which is disposedcentrally' of the carton bottom, both longitudinally and transversely.As will be seen shortly, this post coacts to pro vide support for ahollow formation in the cover when the cover is folded to closedposition.

The cover central construction The cover section 11 is provided with acentral transverse recess 30 formed by the depending wall portions 3131which portions terminate in a transverse wall of special shape. Thus,the transverse wall comprises portions 3232A which, at their outer ends,merge with front and rear central cover planar wall portions 33-34respectively, the latter being extensions of the adjacent planar wallportions 35-36 of the front and rear walls of the top or cover section.

The planar portions 33-34 being in the plane of the front and rear wallsof the cover impart great strength to the carton longitudinally so thatthere is no likelihood of the carton bending or flexing even though itbe packed with eggs liftedby gripping entirely at one end, which, issometimes done in handling the cartons. I The transverse recess in thecenter of the cover is bottomed by the outer portions 3232A which, attheir outer ends, merge with the upper margins of the front and rearcover wall portions 33--34, thence extend inwardly and downwardly wherethey merge with portions 40-41, the latter extending more abruptlydownwardly and inwardly to terminate in a portion 42, which, in theclosed condition of the carton, engages the top portion 2ST of thecentral post C of the bottom section.

As is perhaps best shown in Figs. 1, 2, 3, and 6 the depending wallportions of the cover section, which form the upright wall portions ofthe central transverse recess, LI

comprise, in the closed condition of the carton, central downwardly andinwardly extending portions til-41 and outer curved portions 52, 53, 54,and 55', the latter merging at their inner margins into the planarportions "40-41, and at their outer margins into the upper planarportions of the front and rear walls of the top or cover section.

The cover end construction As is perhaps best shown in Figs. 2, 4, and 7the ends of the cover section are formed generally like the constructionat the transverse center portion. Since each end is alike, a descriptionof one will suffice for both. Centrally, there is, in the closedposition, a downwardly and outwardly extending planar portion 60,bordered front and rear by curved portions 6162, the latter merging intothe planar portions of the front and rear cover walls respectively.

As is best shown in Figs. 4 and 7, the end marginal portions of theflange portion of the cover are provided with offset portions 63-64,which engage the area 65- 66 respectively at the ends of the bottomsection when the cover is folded into closed vposition.

Divisional feature In order to facilitate the division of the cartoninto two parts'both the cover and bottom sections and the locking flapare weakened along the broken line 70. It Will be seen that the line 70extends transversely of the cover and bottom section midway of thetransverse recess in the cover and also extends throughout the planarcentral portions 33 and 34 of the front and rear walls respectively.While the carton can be broken into two parts along this weakened line,nevertheless, the carton is longitudinally of suflicient rigidity toprevent premature 01' accidental rupture along this line. It will benoted that the front and rear central planar wall portions 33 and ,34,respectively, extend upwardly from the general plane on which the coverhinges more than halfway. This construction also permits a substantialcentral portion 18C of the locking flap to be provided without at thesame time interfering with the seating of the cover flange and otherportions on the adjacent bottom marginal portions.

This arrangement, together with the central construction in which themiddle upstanding post 25C of the bottom section supportingly engagesthe depending central portion 42 of the cover when the carton is inclosed con- ,dition, provides the optimum of support and strength withthe very minimum of material.

Another advantage of the carton construction herein disclosed is thateven though there is a transverse recess which facilitates the divisionof the carton into two parts and provides for supporting contact of thebottom section post and a part of the cover, the arrangement is suchthat 'the locking flap has suflicient strength to withstand the stressesencountered in folding it into locking position. This is so whether theflap be folded up by hand or by mechanical devices, in which operationsthe flap is sometimes forced into locking position by engagement withone end only.

Also, when the carton is divided, each section fully protects the eggswhich remain therein.

Thus the several conflicting requirements have been resolved in aconstruction which avoids objections inherent in prior art constructionsand which can be readily molded from pulp stock.

At the same time the structure is such that large eggs can be adequatelyaccommodated, and yet the over-all size of the carton is such as topermit, if desired, the packing of thirty dozen eggs in a standard eggcase.

I claim:

1. A molded pulp egg carton comprising a cover section and a bottomsection integrally connected by a hinge along one side margin thereof,said bottom section being defined by an upwardly extending wallstructure comprising side wall and end wall portions and provided with aplurality of contiguous egg-receiving cells successively arranged in rowformation, said cell-forming structure including at least one row ofhollow upstanding posts extending between opposite end wall portions,said cover section comprising a plurality of panel portions defined bydownwardly extending side and end wall portions and a pair of spaceddownwardly extending transverse wall portions intermediate the end wallportions, said cover side wall portions each including a bridge partintermediate its end, extending upwardly from the lower margins of theside wall portion and terminating in a plane substantially below theplane of the cover panel portions and also below the plane of theuppermost part of the adjacent side wall portions, the ends of saidtransverse wall portions merging into the side wall portions at eachside of said intermediate bridge parts, the lower margins of saidtransverse wall portions being connected by structure at least a portionof which intermediate the cover side wall portions is disposed in aplane to engage the upper end of at least one of said upstanding postsin the bottom section when the cover is in closed position.

2. The carton set forth in claim 1 in which said pair of spaceddownwardly extending transverse wall portions are of greatest depthintermediate the side wall portions and are of progressively less depthoutwardly in the direction of the side wall portions, and being of leastdepth where they merge with the side wall portions.

3. The carton set forth in claim 1 in which the said pair of spaceddownwardly extending transverse wall portions are of such varying depththat the structure connecting the lower margins thereof in transversevertical section define a centrally located bearing portion and portionsat each side thereof extending upwardly and outwardly, finally merginginto the bridge parts of the respective side wall portions.

4. The carton set forth in claim 1 in which the said pair of spaceddownwardly extending transverse wall portions are of such varying depththat the structure connecting the lower margins thereof includes acentrally located intermediate planar portion, portions at each sidethereof extending abruptly upwardly and outwardly, merging with otherportions extending upwardly and outwardly at a lesser angle to saidcentral planar portion, finally merging into the bridge parts of therespective side wall portions.

5. The carton set forth in claim 1 in which the opposite ends of saidpair of transversely extending wall portions are of arcuate constructionas viewed in plan.

6. The carton set forth in claim 1 in which the portion connecting thelower margins of the said pair of transversely disposed wall portion isof planar form, the intermediate portions of said transverse wallportions including planar portions which converge downwardly from theplane of the cover panel portions to merge with margins of saidfirst-mentioned planar portion.

7. The carton structure set forth in claim 1 in which each cover sidewall portion is of planar formation and in which the bridge part thereofis coplanar therewith.

8. A molded pulp egg carton comprising a cover section and a bottomsection integrally connected by a hinge along one side margin thereof,said bottom section being defined by an upwardly extending wallstructure comprising side wall and end wall portions and provided with aplurality of contiguous egg-receiving cells arranged in two rows, saidcell-forming structure including an intermediate row of hollowupstanding posts extending between opposite end wall portions andco-opcrating with the side and end wall portions to define said cells,said end Wall portions comprising a pair of arcuate segments curvingfrom the respective side wall portions toward the center and terminatingin an outwardly extending central flange portion, said cover sectioncomprising a plurality of panel portions defined by downwardly extendingside and end walls and a pair of spaced downwardly extending transversewall portions intermediate the end wall portions, said cover side wallportions each including a bridge part intermediate its ends, extendingupwardly from the lower margins of the side wall portion and terminatingin a plane subtantially below the plane of the cover panel portions andalso below the plane of the uppermost part of the adjacent side wallportions, the ends of said transverse wall portions merging into theside walls at each side of said intermediate bridge parts, the lowermargins of said transverse wall portions being connected by structure atleast a portion of which intermediate the cover side wall portions isdisposed in a plane to engage the upper end of at least one of saidupstanding posts in the bottom section when the cover is in closedposition, the end wall portions of the cover comprising curved partswhich follow substantially the curvature of the end wall parts of thebottom section when the cover is in closed position and which terminatein an outwardly extending central flange portion overlying the centralflange portion of the bottom section.

9. The carton set forth in claim 8 in which the central flanges of saidcover and bottom sections are relatively otfset to provide supportingabutment portions when the cover is in closed position.

10. The carton set forth in claim 8 in which one of aavsnsa flapintegrally connected by a hinge along the other side margin thereof,said bottom section being defined by an upwardly extending wallstructure comprising side Wall and end wall portions and provided with aplurality of contiguous egg-receiving cells successively arranged in rowformation, said cell-forming structure including at least one row ofhollow upstanding posts extending between opposite end wall portions,said cover section comprising a plurality of panel portions defined bydownwardly extending side and end wall portions and a pair of spaceddownwardly extending transverse wall portions intermediate the end wallportions, said cover side wall v portions each including a bridge partintermediate its said central flanges includes an offset portion adaptedto contact with the confronting flange portion of the other section whenthe cover is in closed position.

11. The carton structure set forth in claim 8 in which each of saidpairs of spaced downwardly extending transverse Wall portions comprisesa pair of arcuate segments curving from the respective side wallportions toward the center and merging adjacent the center into acentral wall portion spaced closer to the end wall of the panel, whichit partly defines, than the major portion of said arcuate segments.

12. A molded pulp egg carton comprising a cover section and a bottomsection integrally connected by a hinge along one side margin thereofand a one-piece locking end, extending upwardly from the lower marginsand terminating in a plane substantially below the plane of the coverpanel portions, the ends of said transverse wall portions merging intothe side wall portions at each side of said intermediate bridge parts,the lower margins of said transverse walls being connected by structureat least a portion of which intermediate the cover side wall portions isdisposed in a plane to engage the upper end of at least one of saidupstanding posts in the bottom section when the cover is in closedposition, said locking flap being disposed on the inner side of anadjacent cover side wall when the cover is in closed position andcomprising an intermediate part extending across the bridge part of thecover section and adjoining end parts confronting the inner side ofother parts of said cover wall portion, the latter being of greaterheight than the intermediate part and the entire top marginal portion ofsaid flap terminating at a level substantially below the overlyingportions of cover, thereby permitting the free seating of the lowermarginal portion of one side wall portion of the cover section upon anupwardly facing part of the flap hinge when the cover is in closedposition and also permitting engagement of at least one of theupstanding posts in the bottom section with an overlying dependingportion of the cover intermediate the bridge portions of the cover sidewalls.

13. The carton set forth in claim 12, including structure in which theside wall portion of the cover section on the inner side of which thesaid flap is disposed when the cover is in closed position including aplurality of apertures, and said fiap including a plurality ofprojections formed and adapted to enter said apertures when the cover isfolded to closed position, thereby serving to hold the sections againstaccidental swinging movement.

References Cited in the file of this patent UNITED STATES PATENTS2,100,516 Read Nov. 30, 1937 2,160,893 Newsom June 6, 1939 2,529,140 CoxNov. 7, 1950 2,560,847 Chaplin July 17, 1951 2,771,233 Cox Nov. 20, 1956FOREIGN PATENTS 164,896 Australia July 2, 1953 '771,552 Great BritainApr. 3, 1957

